Method and apparatus for modifying flow

ABSTRACT

Disclosed herein are apparatuses and methods for packing off or choking a radial flow port through a tubular. In some embodiments, the apparatuses and methods comprise a support element and a polymeric element surrounding the support element. The polymeric element closes or chokes the radial flow port when contacted with the tubular.

REFERENCE TO RELATED APPLICATIONS

This application claims priority to Provisional U.S. patent application Ser. No. 61/060,912 filed on Jun. 12, 2008, incorporated herein by reference.

BACKGROUND

Well completion equipment is used in a variety of well related applications involving, for example, the production of fluids. The completion equipment is deployed in a wellbore and often comprises one or more devices or valves for controlling fluid flow in the well. Particularly, in some circumstances, a flow control device will control the radial flow of fluid through a tubular element.

If a flow control device malfunctions or becomes inoperable, the impact of such failure can be significant. For example, it may disrupt production, permanently affect productivity, and/or require additional capital and workover expenditures. Because the potential cost of a failure may be substantial, measures may be taken up front to mitigate the risk of malfunction or failure.

One method to mitigate risk is shown in FIG. 1, wherein a tubular 10, has flow ports 20 therethrough. The flow ports, although shown schematically, may be openings in a flow control device such as an inflow control device (ICD). If it is desirable to close off flow ports 20 (e.g., because of a malfunction causing the flow ports to undesirably remain open), a straddle sleeve 30 may be deployed downhole, via slick line, coiled tubing, or any other suitable conveyance method. The straddle sleeve is comprised of seals 40 and locating and locking profile 60. When run in hole, the sleeve 30 is run until the locking profile 60 engages with a similarly shaped locating and locking profile that has been cut into the inside of the tubular 10. This method may seal off the faulty flow ports, but it also undesirably restricts the throughbore ID of the tubular 10. This reduction of throughbore ID may impact future access to lower zones and may choke production through the affected tubular section.

SUMMARY

Disclosed herein are apparatuses and methods for packing off or choking a radial flow port through a tubular. In some embodiments, the apparatuses and methods comprise a support element and a polymeric element surrounding the support element. The polymeric element closes or chokes the radial flow port when contacted with the tubular. In some embodiments, the polymeric element may comprise an elastomer and/or a swellable material. In some embodiments, the support element may be a radial spring or an expandable tubular element.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a straddle sleeve installed to close flow ports.

FIG. 2 is a schematic drawing of a device installed to close flow ports.

FIG. 3 is a schematic drawing of a device installed to close flow ports.

DETAILED DESCRIPTION

Referring to FIG. 2, there is shown a tubular 110, having recess 160, flow ports 120, and locating profile 150. In operation, prior to intervention, tubular 110 and flow ports 120 may be a flow control device, such as an ICD or flow control valve. If a failure or default occurs, flow ports 120 may undesirably remain in the open position. By way of example only, in the case of a production ICD, this may be undesirable because once water begins flowing through the ICD, it may be desirable to close off the ICD to reduce the water in the production fluids.

In order to remedy the failure of the flow ports to properly close, in the embodiment shown in FIG. 2, an intervention element comprising contracted radial spring element 140 and flexible member 130 is run in hole adjacent to the location of the malfunctioning flow ports. One way of locating the proper placement for the intervention element is by the use of a locator element on the running tool used to run the intervention device (not shown). The locator element preferably have a profile to match the locator profile of the tubular 150. No particular locator profile is necessary, so long as it is sufficient to allow the operator to locate flow ports 120 to be close off. Once in place, the radial spring element 140 is allowed to expand into recess 160. Once expanded, flexible member 130 is pressed against tubular 110 and prevents flow through flow ports 120. The expansion may be triggered by the running tool releasing tension on the spring or by some other mechanism. For example, the spring could be held in a contracted state by a material that is designed to degrade or dissolve in the wellbore conditions, e.g., due to temperature or reaction with wellbore fluids.

In preferred embodiments, flexible member 130 is an elastomeric polymer that maintains its integrity in wellbore conditions. By way of example only, flexible member 130 may be an oil swellable elastomer made of elastomers that contain polyolefins, polybutadiene or polysioprene. The flexible member can be made of a water swellable elastomer. The flexible member may, if needed for the application, be a swellable material that swells in the presence of hydrocarbon fluids, water-containing fluids, brine, or any combination. By way of example only, the swellable material disclosed in U.S. Pat. No. 7,373,991 may be used. U.S. Pat. No. 7,373,991 teaches, among other things, an elastomeric composition comprising the reaction product of a linear or branched polymer having residual ethylenic unsaturation with an ethylenically unsaturated organic monomer having at least one reactive moiety selected from acid, acid anhydride, and acid salt, or allyl alcohol, the elastomeric composition formed into an oilfield element.

In addition, flexible member 130 may be a sleeve that completely surrounds spring element 140 or spring member 140 may be embedded or molded, completely or partially within flexible member 130, such that flexible member 130 and spring member 140 are a unitary body. In these configurations, the spring acts as a back-up, anti-extrusion device, and seal energizer for the flexible member.

Referring now to FIG. 3, there is shown a tubular 210, having recess 250, flow ports 220, and locating profile 260. In operation, prior to intervention, tubular 210 and flow ports 220 may be a flow control device, such as an ICD or flow control valve. As discussed above with respect to FIG. 2, if a failure or default occurs, flow ports 220 may undesirably remain in the open position. By way of example only, in the case of a production ICD, this may be undesirable because once water begins flowing through the ICD, it may be desirable to close off the ICD to reduce the water in the production fluids.

In order to remedy the failure of the flow ports to properly close, in the embodiment shown in FIG. 3, an intervention element comprising an expandable element 240 and flexible member 230 is run in hole adjacent to the location of the malfunctioning flow ports. One way of locating the proper placement for the intervention element is by the use of a locator element on the running tool used to run the intervention device (not shown). The locator element preferably have a profile to match the locator profile of the tubular 260. No particular locator profile is necessary, so long as it is sufficient to allow the operator to locate flow ports 220 to be closed off. Once in place, the expandable element 240 is expanded into recess 250. Once expanded, flexible member 230 is pressed against tubular 210 and prevents flow through flow ports 120.

With respect to expansion mechanisms, any acceptable expandable element can be used. Nonexclusive examples of expansion elements that may be used are shown in U.S. Pat. Nos. 7,398,831 and 7,185,709 and European Patent No. EP1717411. The expansion mechanism of U.S. Pat. No. 7,398,831 utilizes, e.g., a device having a plurality of bistable cells formed into a tubular shape. Each bistable cell comprises at least two elongated members that are connected to each other at their ends. Likewise, U.S. Pat. No. 7,185,709 teaches, e.g., an expandable bistable device. EP1717411, for example, teaches a mechanism for deforming a tubular radially outwardly (i.e., expanding the tubular).

As above, in preferred embodiments, flexible member 230 is an elastomeric polymer that maintains its integrity in wellbore conditions. By way of example only, flexible member 230 may be an oil swellable elastomer made of elastomers that contain polyolefins, polybutadiene or polysioprene. The flexible member can be made of a water swellable elastomer. Flexible member 230 may also be a swellable material, such as is described above. In addition, flexible member 230 may be a sleeve that completely surrounds expandable element 240 or expandable member 240 may be embedded or molded, completely or partially within flexible member 230, such that flexible member 230 and expandable member 240 are a unitary body. In these configurations, the expandable element acts as a back-up, anti-extrusion device, and seal energizer for the flexible member.

In alternative embodiments, rather than completely block the flow of fluids through the flow ports, the apparatus may contain radial flow ports which only choke the flow of fluids through the flow ports. For example, the total flow area of the radial flow ports in the expandable device may preferably be less than that of the flow ports being choked.

Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. 

1. An apparatus for packing off a radial flow port through a tubular comprising: a support element; and a polymeric element surrounding the support element, wherein the polymeric element closes the radial flow port when contacted with the tubular.
 2. The apparatus of claim 1 wherein the polymeric element is a swellable elastomer.
 3. The apparatus of claim 1 wherein the polymeric element is an elastomer.
 4. The apparatus of claim 1 wherein the polymeric element is swellable.
 5. The apparatus of claim 4 wherein the polymeric element swells in the presence of oil.
 6. The apparatus of claim 4 wherein the polymeric element swells in the presence of a water-containing fluid.
 7. The apparatus of claim 1 wherein the support element is a radial spring element.
 8. The apparatus of claim 1 wherein the support element is an expandable tubular element.
 9. A method for closing a radial flow port through a tubular comprising: providing a pack off element radially inward from the radial flow port, wherein the pack off element comprises a support element and a polymeric element; contacting the polymeric element with the radial flow port to close the radial flow port.
 10. The method of claim 9 wherein the polymeric element is a swellable elastomer.
 11. The method of claim 9 wherein the polymeric element is an elastomer.
 12. The method of claim 9 wherein the polymeric element is swellable.
 13. The method of claim 12 wherein the polymeric element swells in the presence of oil.
 14. The method of claim 12 wherein the polymeric element swells in the presence of a water-containing fluid.
 15. The method of claim 9 wherein the support element is a radial spring element.
 16. The method of claim 9 wherein the support element is an expandable tubular element.
 17. An apparatus for choking flow through a radial flow port through a tubular comprising: a support element; and a polymeric element surrounding the support element, wherein the polymeric element chokes flow through the radial flow port when contacted with the tubular.
 18. The apparatus of claim 17 wherein the support element is a radial spring element.
 19. The apparatus of claim 17 wherein the support element is an expandable tubular element.
 20. The apparatus of claim 17 wherein the polymeric element is an elastomer. 